Fuel Rail: Service and Repair

Fuel Rail

Special Service Tools







Fuel spring lock decoupling tool
310-005

Removal

WARNING:
^ Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
^ Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

1. Disconnect the battery ground cable.
2. Remove the engine cover.
3. Remove the purge valve assembly.
4. Release the heater hose support bracket.
^ Remove the 3 nuts.
^ Tie the bracket aside.







5. Remove the LH engine cover bracket.
^ Release the electrical connector.







6. Remove the RH engine cover bracket.
^ Remove the 2 nuts.
^ Remove the bolt.
^ Release the electrical connector.







CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.

7. Disconnect the crankcase vent hoses.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

8. Using the special tool, disconnect the fuel line.
^ Position an absorbent cloth to collect fluid spillage.







9. Position the wiring harness support bracket aside for access.
^ Remove the 2 bolts.







10. Release the engine wiring harness clips.
^ Release the 4 clips.
^ Remove the 2 bolts.

11. Disconnect the fuel injector electrical connectors.







12. Disconnect the engine gas recirculation modulator electrical connection.







13. Disconnect the fuel temperature sensor electrical connector.

NOTE: Do not disassemble further if the component is removed for access only.

14. Remove the fuel rail.
^ Remove the 4 Torx bolts.
^ Remove and discard the fuel injector O-ring seals.






15. Remove the fuel temperature sensor.
16. Remove the fuel injectors.
^ Remove the retaining clips.
^ Release the fuel injectors.
^ Remove and discard the fuel injector O-ring seals.







Installation
1. Clean the components.
2. Install the fuel injectors to the fuel rail.
^ Install fuel injector O-ring seals.
^ Lubricate the O-ring seals with clean engine oil.
^ Install the fuel injectors.
^ Secure the fuel injector retaining clips.

3. Install the fuel temperature sensor.
^ Tighten the sensor to 10 Nm (7 ft. lbs.).

4. Install the fuel rail.
^ Install fuel injector O-ring seals.
^ Lubricate the O-ring seals with clean engine oil.

5. Connect the fuel temperature sensor electrical connector.
6. Connect the fuel injector electrical connectors.
7. Connect the engine wiring harness to the intake manifold.
^ Tighten the M6 bolts to 10 Nm (7 ft. lbs.).

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.

8. Connect the fuel line to the fuel rail.
^ Clean the component mating faces.
^ Position the fuel pipe into clips.

9. Connect the crankcase vent hoses.
^ Clean the component mating faces.

10. Install the engine cover mounting brackets.
^ Tighten the nuts to 6 Nm (4 ft. lbs.).
^ Attach the wiring harness connector blocks to the brackets.

11. Install the heater hose support bracket.
^ Tighten the nuts to 10 Nm (7 ft. lbs.).

12. Check and top-up the coolant if required.
13. Install the engine cover.
14. Install the purge valve.
15. Connect the battery ground cable.